Compression fabric manufacturing process

ABSTRACT

A method for manufacturing a compression performance fabric is provided. In an embodiment of the invention, different yarns can be attached to a single jersey circular knitting machine. The yarns can include polyamide yarn and an elastane yarn. The single jersey circular knitting machine can be configured to create a fabric that includes a a three to one ratio (3:1) of polyamide to elastane and a fabric density of at least three hundred grams per square meter but no more than three hundred eighty grams per square meter can be created. Thereafter, the created fabric can be finished for use in producing apparel including performance apparel.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to the manufacture of fabric and more particularly to manufacture of performance and compression fabric.

2. Description of the Related Art

A textile is a flexible woven material consisting of a network of natural or artificial fibers often referred to as thread or yarn. Yarn is produced by spinning raw fibers of wool, flax, cotton, or other material to produce long strands. Yarn, and hence textiles, come from four main sources: animal (wool, silk), plant (cotton, flax, jute), mineral (asbestos, glass fiber), and synthetic (nylon, polyester, acrylic, elastane). Nylon is a generic designation for a family of synthetic polymers known generically as polyamides. Nylon 6-6 (nylon 6,6) and nylon 6 (polyamide 6) are the two most common forms of nylon used in the textile and plastics industries. Elastane or spandex is a synthetic fiber, which is a polyurethane product, usually a polyurethane-polyurea copolymer. Yarns of different origins, lengths, thickness, or color can be also be blended to create yarns with desirable characteristics, such as strength or durability. Fabrics created from such fibers are called blends. Typically, in a blend involving elastane, there is a one-to-one ratio or a one and a half to one ratio of a hard yarn to elastane (a soft yarn). In this way, a hard yarn is paired with a soft yarn to give stretch to the resulting fabric.

Textiles are formed by weaving, knitting, crocheting, knotting, or pressing fibers together. Though the terms fabric and cloth are usually used in textile assemble trades as synonyms for textiles, there can actually be subtle differences. Textile refers to any material made of interlacing fibers. Fabric refers to any material made through weaving, knitting, spreading, crocheting, or bonding that may be used in production of further goods. Cloth may be used synonymously with fabric but often refers to a finished piece of fabric used for a specific purpose. Textiles are made in various strengths and degree of durability with the relative thickness of fibers in cloth being measured in deniers.

There are several methods of manufacturing synthetic fibers, including, but not limited to melt-spinning and solution dry spinning. The fibers can be further processed, such as coated, to enhance or provide desirable properties, such as to produce a flame retardant fabric or a colorfast fabric. Yarn can be produced from the fibers, by slicing the raw materials, melting the raw materials and well as shaping and blending using high atmospheric pressure. If desired, the yarn can also be further processed, such as coated. Before the fabric is used to create a product, the fabric can further go through several finishing processes, such as desizing, heat-setting, bleaching, anti-microbial finishing, etc. to improve the look, performance, or feel of the finished product.

A fabric produced according to the manufacturer of synthetic fiber can demonstrate specific qualities suitable for a particular use. One particular use is athletic performance wear. A fabric produced for athletic performance wear is referred to as a “performance fabric” and includes fabrics made for a variety of end-use applications, which provide functional qualities, such as moisture management, UV protection, anti-microbial, thermo-regulation, and wind/water resistance. Related to a performance fabric, a compression fabric is a high tenacity stretch fabric which, when in a close fitting garment, provides muscles with a firm compression fit that lessons vibrations, reduces fatigue, and keeps muscles energized. A compression fabric usually is made in a knit construction, using a series of gradient fibers with an open knit inner surface to create a moisture transfer environment.

BRIEF SUMMARY OF THE INVENTION

Embodiments of the present invention address deficiencies of the art in respect to performance and compression fabrics and provide a novel and non-obvious process for producing a compression fabric. In an embodiment of the different yarns can be attached to a single jersey circular knitting machine. For instance, the yarns can include a one hundred sixty deniers and one hundred forty four filament (160D/144F) polyamide yarn and a seventy deniers (70D) elastane yarn. The single jersey circular knitting machine can be configured to create a fabric of a three to one (3:1) ratio of polyamide to elastane. Consequently, the knitting machine can produce a fabric demonstrating a density of at least three hundred grams per square meter but no more than three hundred eighty grams per square meter. Subsequently, the created fabric can be finished for use in producing apparel such as performance wear.

Additional aspects of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The aspects of the invention will be realized and attained by means of the elements and combinations particularly pointed out in the appended claims. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention, as claimed.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute part of this specification, illustrate embodiments of the invention and together with the description, serve to explain the principles of the invention. The embodiments illustrated herein are presently preferred; it being understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown, wherein:

FIG. 1 is a pictorial illustration of a process for manufacturing a compression fabric; and,

FIG. 2 is a flow chart illustrating a process for manufacturing a compression fabric.

DETAILED DESCRIPTION OF THE INVENTION

Embodiments of the invention provide for a manufacturing process to manufacture a compression fabric. In accordance with an embodiment of the invention, multiple, different yarns can be introduced into a single jersey knitting machine. Amongst the different yarns, a polyamide yarn as well as an elastance yarn can be included. The single jersey knitting machine can be configured to create a polyamide/elastane fabric having a three to one ratio of polyamide to elastane. In this way, the knitting machine can manufacture a high compression fabric that, among other things, compresses an enclosed body more than the fabric stretches. Thereafter, the fabric can be finished to exhibit additional fabric qualities resulting in a finished compression fabric of a density between at least three hundred grams per square meter, but no more than three hundred eighty grams per square meter. The finished fabric in turn can be used to produce finished textile products, such as pants, shirts, and dresses.

In further illustration, FIG. 1 depicts a process for manufacturing a compression fabric. As shown in FIG. 1, multiple, different yarns 110 can be attached to a knitting machine 150. In one embodiment, the multiple, different yarns 110 can include a one hundred sixty deniers and one hundred forty four filament (160D/144F) polyamide yarn and a seventy deniers (70D) elastane yarn. In a different embodiment, the elastane yarn can a thickness in the range of no less than seventy deniers and no more than one hundred forty deniers, though other thicknesses are possible for each of the elastane yarn and the polyamide yarn. Once the yarn 110 is attached to a knitting machine 150, the knitting machine 150 can be configured 135 to create a fabric comprising a three to one ratio of polyamide to elastane. This configuration 135 can include, but is not limited to, setting the speed of the knitting machine 150, the yarn tension, the dial scale index, runner length, and the feed rate of each yarn 110 into the machine.

In addition, a variety of different type of needles as well as mechanical components of the knitting machine 150 can be arranged to produced the desired fabric 160. In one instance, the knitting machine 150 can be set to revolve at twenty revolutions per minute. Further, in one embodiment the yarn tension can be set so the yard tension on a tensiometer reads about six grams. In another embodiment, the yard tension can be set so to read between about six grams and about ten grams. Further, in an embodiment the polyamide yarn can be fed at a rate of thirty six centimeters per one hundred needles and the elastane can be fed at a rate of twelve centimeters per one hundred needles. In addition, the knitting machine 150 can be configured to create a fabric 160 with a ratio of three to one (3:1) of polyamide to elastane. In this way, a fabric 160 with a high compression (as opposed to high stretch) can be created.

Upon the configuration 135 of the knitting machine 150, the knitting machine 150 can be operated in order to create the fabric 160. The fabric 160 created can include a blend of polyamide and elastane. In an embodiment, the blend can be an eighty seven percent polyamide (87%) and a thirteen percent elastane (13%) blend. In a different embodiment, the range of polyamide can be no less than approximately eighty six percent (86%) and no more than about eighty eight percent (88%) and the range of elastane can be no less than about twelve percent (12%) and no more than about fourteen percent (14%). In an even different embodiment, the range of polyamide can be no less than about ninety percent (90%) and no more than about ninety two percent (92%) and the range of elastane can be no less than about eight percent (8%) and no more than about ten percent (10%).

Of note, the knitting machine 150 can be a single jersey circular knitting machine. In an embodiment, a knitting machine 150 that is a single jersey circular knitting machine can have a diameter of thirty four inches, a gauge of 28 (needles per inch), a wheel feeder, a speed of twenty revolutions per minute, and a yard spreader of three centimeters. In addition, the knitting machine 150 can include 120 yarn holes.

Upon the production of the fabric 160 by the knitting machine 150, the fabric 160 can be further finished 175. In one embodiment, the finishing 175 process can include slitting and spreading the fabric 160 so to double size of the fabric from a width of about 76.2 centimeters (thirty inches) when the fabric 160 is removed from a knitting machine 150 to a width of about 152.4 centimeters (sixty inches). Further, the fabric 160 can be placed in a curing oven or a tinter frame in which the fabric 160 can be processed. While in the tinter frame or separate from it, the fabric 160 can have multiple, different chemicals applied to it to improve the look, performance, or feel of what will be used to create a finished product 199. For example, the fabric 160 can have different chemicals applied to it, which improves the performance of an end product 199. For instance, finishes (chemicals) directed to anti-pilling, anti-static, and anti-microbial properties can be applied to the fabric 160. Further, additional finishing processing 175 can include the addition of chemicals through microencapsulation. Microencapsulation can include the introduction of chemicals, creams, and the like, such as moisturizers, acne control agents, serums, vitamins, insulin, etc. that can be absorbed by the skin of an end user via the fabric 160 over time.

In addition, finish processes 175 directed to improve an end product's 199 anti-odor properties, colorfastness, anti-bacterial, soil release, wrinkle resistance, ultraviolet protection, wicking, flame resistance capability, and ultraviolet protection factor can also be applied. In this way, the finishing process directed to ultraviolet protection creates a finished fabric 185 that conforms to the American Society for Testing and Materials (ASTM) D6603 standard for labeling of UV-protective textiles for a labeling category of excellent UV protection. Further, the finished fabric 185 can be created so that it has an ultraviolet protection factor of at least fifty. Once the fabric 160 has gone through the finishing process 175, the finished fabric 185 can be used to create end products 199, such as dresses, shirts, and pants. Of note, besides clothing, the fabric 160 can be utilized for other things, such as for upholstery and performance bedding. The finished fabric 185 formed can have a weight of no less than about three hundred forty grams per square meter and no more than about three hundred eighty grams per square meter. In addition, the finished fabric 185 can have a stretch length of eighty five percent (85%) and a stretch width of one hundred five percent (105%).

In further illustration of the process described in FIG. 1, FIG. 2 is a flow chart illustrating a process for manufacturing a compression fabric. Starting in block 205, multiple, different yarns can be attached to a single jersey circular knitting machine. In one embodiment, one yarn can be a one hundred sixty deniers and one hundred forty four filament (160D/144F) polyamide yarn and a different yarn can be a seventy deniers (70D) elastane yarn. In another embodiment, the elastane yarn can be in the range of no less than seventy deniers and not more than one hundred forty deniers. Once the different yarns have been attached to a knitting machine, the knitting machine can be configured, as shown in block 210. Configuration can include, but is not limited to, setting the speed of the knitting machine, the yarn tension, the dial scale index, the runner length, and the feed rate of each yarn into the machine. In addition, a variety of different type of needles as well as mechanical components of the knitting machine can be arranged to produce the desired fabric. In one embodiment, the knitting machine can be configured to produce a fabric with a ratio of three-to-one (3:1) of polyamide to elastane. In one embodiment, this can be accomplished by setting the polyamide to feed at a rate of thirty six centimeters per one hundred needles and the elastane to feed at a rate of twelve centimeters per one hundred needles.

Of note, the knitting machine can also be configured to create a fabric comprising different polyamide and elastane blends. For example, the blend can be an eighty seven percent (87%) polyamide and a thirteen percent (13%) elastane blend. In a different embodiment, the range of polyamide can be no less than approximately eighty six percent (86%) and no more than about eighty eight percent (88%) and the range of elastane can be no less than about twelve percent (12%) and no more than about fourteen percent (14%). In an even different embodiment, the range of polyamide can be no less than about ninety percent (90%) and no more than about ninety two percent (92%) and the range of elastane can be no less than about eight percent (8%) and no more than about ten percent (10%).

Upon configuring the knitting machine, the machine can be operated to create loose cloth, as illustrated in block 215. Once the loose cloth is created, the cloth can be subjected to multiple, different finishing processes. In this regard, the finishing processes can occur in a tinter frame, which can include multiple, different zones, where each zone can be set to specific temperature and dwell times, so that the cloth travels through the tinter frame at an appropriate rate in order to be properly finished. In block 220, the cloth can be desized, which is one such finishing process. The desized cloth can then go through high temperature consolidation, as shown in block 225, followed by dyeing, as indicated in block 230. Of note, the high temperature consolidation can be conducted at a temperature of about one hundred ninety degrees Celsius.

Upon dyeing, the cloth can be dried, as indicated in block 235. Following the drying process, a second high temperature consolidation process can take place at one hundred seventy degrees Celsius, as shown in block 240. The finished fabric can then be rolled, as in block 245, and put in storage. Of note, the finished fabric can have a weight of at least three hundred forty grams per square meter to no greater than three hundred eighty grams per square meter. In addition, the finished fabric can have a stretch length of eighty five percent (85%) and a stretch width of one hundred five percent (105%). The finishing processes conducted on the fabric can result in the fabric having different characteristics. For example, via a finishing process directed at ultraviolet protection, a finished fabric that conforms to the American Society for Testing and Materials (ASTM) D6603 standard for labeling of UV-protective textiles for a labeling category of excellent UV protection can be produced. Further, the finished fabric can have an ultraviolet protection factor of no less than fifty. Additional finishing processing can include the addition of chemicals through microencapsulation. Microencapsulation can include the introduction of chemicals, creams, and the like, such as moisturizers, acne control agents, serums, vitamins, insulin, etc. that can be absorbed by the skin of an end user via the fabric 160 over time. The stored fabric can then be used to produce finished products, including, but not limited to pants, shirts, dresses, and upholstery.

Having thus described the invention of the present application in detail and by reference to embodiments thereof, it will be apparent that modifications and variations are possible without departing from the scope of the invention defined in the appended claims as follows: 

I claim:
 1. A method for making a fabric comprising: attaching a plurality of yarns to a single jersey circular knitting machine, the plurality of yarns comprising a polyamide yarn and an elastane yarn; configuring a single jersey circular knitting machine to create a fabric comprising a three to one ratio (3:1) of polyamide to elastane; and, finishing the created fabric.
 2. The method of claim 1, wherein the created fabric comprises eight seven percent of polyamide and thirteen percent of elastane.
 3. The method of claim 1, wherein the finished fabric conforms to an excellent UV protection labeling category for a labeling of UV-protective textiles standard.
 4. The method of claim 1, wherein the created fabric comprises at least no less than eighty six percent of polyamide and no more than eighty eight percent of polyamide.
 5. The method of claim 1, wherein the created fabric comprises at least no less than twelve percent of elastane and no more than fourteen percent of elastane.
 6. The method of claim 1, wherein the finished fabric has an ultraviolet protection factor of at least fifty.
 7. The method of claim 1, wherein finishing the created fabric comprises dyeing the fabric.
 8. The method of claim 1, wherein the yarns comprise a one hundred sixty deniers and one hundred forty four filament (160D/144F) polyamide yarn and a seventy deniers (70D) elastane yarn.
 9. The method of claim 1, wherein the created fabric has density of at least three hundred grams per square meter, but no more than three hundred eighty grams per square meter.
 10. A compression fabric prepared by a process comprising the steps of: attaching a plurality of yarns to a single jersey circular knitting machine, the plurality of yarns comprising a polyamide yarn and an elastane yarn; configuring a single jersey circular knitting machine to create a fabric comprising a three to one ratio (3:1) of polyamide to elastane; and, finishing the created fabric.
 11. The compression fabric of claim 10, wherein the created fabric comprises eighty seven percent of polyamide and thirteen percent of elastane.
 12. The compression fabric of claim 10, wherein the finished fabric conforms to the American Society for Testing and Materials (ASTM) D6603 standard for labeling of UV-protective textiles for a labeling category of excellent UV protection.
 13. The compression fabric of claim 10, wherein the finished fabric has an ultraviolet protection factor of at least fifty.
 14. The compression fabric of claim 10, wherein the created fabric comprises at least no less than ninety percent of polyamide and no more than ninety two percent of polyamide.
 15. The compression fabric of claim 10, wherein the created fabric comprises at least no less than eight percent of elastane and no more than ten percent of elastane.
 16. The compression fabric of claim 10, wherein finishing the created fabric comprises microencapsulation of the created fabric.
 17. The compression fabric of claim 10, wherein the yarns comprise a one hundred sixty deniers and one hundred forty four filament (160D/144F) polyamide yarn and a seventy deniers (70D) elastane yarn.
 18. The compression fabric of claim 10, wherein the created fabric has density of at least three hundred grams per square meter, but no more than three hundred eighty grams per square meter.
 19. The compression fabric of claim 10, wherein the created fabric has a stretch length of eight five percent.
 20. The compression fabric of claim 10, wherein the created fabric has a stretch width of one hundred five percent. 